1. Shaft Replacement Standard Operating Procedure

2. Disconnect EMAs X Axis EMA Y Axis
Tools Needed: Snap Ring Pliers, Computer, EMA Software
Step 1: Remove pin ring from EMA clevis and load cell
If using new joint: Just retract EMA with the software.
Y Axis
Tools Needed: 7/8 wrench, Computer, EMA Software
Step 1: Remove pin from EMA clevis and load cell
Step 2: Retract EMA using the software

3. Moving EMAs Flip Breaker to turn on power to EMA controllers
Plug in cables to EMA-1
Open Moog GUI
Go to motion tab and change position
Click download pointing arrow in top left to download setup to the controller
Open NI MAX
Reset the USB-6216 DAQ device
Set analog channel output to zero along with its minimum

4. Moving EMAs 2
Plug in serial cable to EMA-2 (Repeat previous slide steps)
Open Moog GUI and select “Use current model” ( )
Go to motion tab and change position
Click download pointing arrow in top left to download setup to the controller
Open NI MAX
Reset the USB-6216 DAQ device
Set analog channel output to zero along with its minimum

5. Outlet Flow Inlet Removal
Tools Needed: Adjustable wrench, bucket
Step1: Using adjustable wrench, unscrew oil inlet hose, pour excess oil into bucket.
Step 2: Remove oil inlet adapter from bearing housing using the adjustable wrench

6. LVDT and The Tools needed: 3/8 allen key, 3/4 wrench
Step 1: Removal thermocouple from housing by hand.
Step 2: Remove LVDT’s from LVDT fixture
Step 3: Using the 3/8 Allen key and 3/4 wrench, unscrew the LVDT fixture from the rig

7. Oil Outlet Removal Tools needed: 7/8 wrench, bucket
Step 1: Using the adjustable wrench, unscrew all outlet hoses, pour excess oil into bucket

8. Remove the Encoder Tools needed: 3/32 Allen key, flathead screwdriver
Step 1: Using the flathead screwdriver, unscrew the encoder from the table
Step 2: Using the Allen key, unscrew the setscrews in the encoder, releasing it from the journal

9. Remove the V-Belt and the Pulley
Tools needed: 5/32 Allen key
Step 1: Remove v-belt safety cover from top of table
Step 2: Using the Allen key, unscrew the setscrew holding the V-belt pulley to the journal
Step 3: Pull back on the pulley to stretch the V-belt and simultaneously pull off the journal
Step 4: Set belt and pulley off to the side

10. Remove Pillow Bearing Tops
Tools needed: 9/16 Socket, Ratchet
Step 1: Using the socket and ratchet, loosen pillow block bearing bolts
Step 2: Finish unscrewing the bolts by hand

11. Remove Load Cells Tools Needed: Adjustable wrench
Step 1: Using the adjustable wrench, loosen load cell, unscrew the rest by hand to avoid tangling the wires.
Step 2: Preferably with a partner, pick up and rotate housing so Y-load cell is now rotated 90 degrees.
Step 3: Using wrench, remove the Y-load cell

12. Remove Journal From Housing
Tools needed: 3/16 Allen key
Step 1: Using Allen key, loosen set screws
Step 2: Remove busing insert by pulling it away from the housing
Step 3: Slowly remove the journal from the bearing housing.

13. Replace Journal Shaft

14. Installing the Journal **********
Tools needed: Oil
Step 1: Lubricate the journal shaft
Step 2: Check to make sure you are installing from the CORRECT SIDE.
Step 3: Insert shaft until it comes close to the other side. You should be able to support it from the other side
Step 4: Holding the journal shaft from both ends, twist it until you feel that it is centered with the journal bearing and push it the rest of the way into the housing.

15. Installing the Bushing Insert
Tools needed: Oil and 3/16 Allen Key
Step 1: Lubricate the journal and bearing insert.
Step 2: Check orientation of flat spots in the journal and orient the insert accordingly.
Step 3: Use the Allen key to tighten set screws, fixing the bearing insert to the journal.

16. Install Load Cells Tools Needed: Adjustable wrench
Step 1: Locate the correct orientation for installment
Step 2: Hand tighten the X-load cell
Step 3: With help, rotate the housing to access the Y-load cell, and using the wrench, tighten the Y-mount
Step 4: Ensure the load cells are in the correct orientation for connection to EMAs

17. Reinstall Oil Hoses
Tools needed: 7/8 wrench, adjustable wrench, bucket
Step 1: Install oil inlet adapter
Step 2: Screw on oil inlet hose first
Step 3: Screw on both outlet hoses last

18. Install Sensors and V-Belt
Tools needed: 5/32, 3/32, 3/8 Allen key, 3/4 wrench and flat head
Step 1: Place thermocouple in oil outlet adapter
Step 2: Place encoder on journal
Using the flat head screwdriver, screw in until washing has firmly pressed bracket to the sheet metal
Using the 3/32 Allen key, tighten the set screws
Step 3: Place pulley on the journal
Locate the flat of the journal
Orient V-belt pulley so set screw is in line with the journal’s flat
Using the 5/32 Allen key, tighten set screw
Step 4: replace LVDTs
Place mount so bottom tip is against the table top
Use 3/8 Allen key and the 3/4 wrench to tighten the mount against the table
Place the LVDTs back in the slots but them from touching the housing until after the EMAs are hooked up.
Tighten LVDTs down with 4-40 screws

19. Connect EMAs to the Housing
Tools needed: Computer, EMA software
Step 1: Flip the breaker to turn on the power to the EMA controllers
Step 2: Plug in serial cable to EMA-1
Step 3: Open up Moog GUI and select “use current model” ( )
Reset fault
Step 5: Open NI MAX
Reset the USB-6216 DAQ device.
Open test panel
Set analog output channel zero min to 0 and the max to 10V
Divide the starting position by max length and multiply by 10
Use this voltage to move EMA to original position
Adjust voltage incrementally until the rod end and clevis line up
Step 6: Unplug power chord to EMA
Step 7: Place pin and replace snap ring

20. Connect the EMAs to the Housing
Step 1: Plug in serial cable to EMA-2
Step 2: Open up Moog GUI and select “use current model” ( )
Rest fault
Step 3: Plug in the EMA power cord
Reset the USB-6216 DAQ device
Step 4: Open the NI MAX
Reset the USB-6216 DAQ device.
Open test panel
Set analog output channel zero min to 0 and the max to 10V
Divide the starting position by max length and multiply by 10
Use this voltage to move EMA to original position
Adjust voltage incrementally until the rod end and clevis line up
Step 5: Unplug power cord to EMA
Step 6: Place pin and hand tighten nut

21. Connect EMAs to the Housing
Step 1: Plug in serial cable to the EMA-1
Step 2: Open up MOOG GUI and select “Use Current Model” ( )
Reset fault
Go to motion tab and change to open loop force
Click downward pointing arrow in top left to download setup to the controller
Step 3: Plug in serial cable to the EMA-2
Step 4: Open up MOOG GUI and select “Use Current Model” ( )